Methods of using invert emulsion fluids with high internal phase concentration

ABSTRACT

In a method of gravel packing a wellbore in a subterranean formation, the wellbore comprising a cased section and an uncased section, the method may include pumping into the wellbore a gravel pack composition comprising gravel and a carrier fluid comprising an invert emulsion fluid, where the invert emulsion fluid may comprise: an oleaginous external phase; a non-oleaginous internal phase, wherein a ratio of the oleaginous external phase and non-oleaginous internal phase is less than 50:50 and an emulsifier stabilizing the oleaginous external phase and the non-oleaginous internal phase.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional filed pursuant to 35 U.S.C. §121 ofU.S. patent application Ser. No. 13/053,990 filed Mar. 22, 2011, whichis a continuation-in-part of PCT/US2010/049752 filed on Sep. 22, 2010,the contents of which are incorporated by reference in their entirety.

BACKGROUND OF INVENTION

Field of the Invention

Embodiments disclosed herein relate generally to invert emulsionwellbore fluids. In particular, embodiments disclosed herein relate toinvert emulsion fluid having a high internal phase concentration.

Background Art

During the drilling of a wellbore, various fluids are typically used inthe well for a variety of functions. The fluids may be circulatedthrough a drill pipe and drill bit into the wellbore, and then maysubsequently flow upward through wellbore to the surface. During thiscirculation, the drilling fluid may act to remove drill cuttings fromthe bottom of the hole to the surface, to suspend cuttings and weightingmaterial when circulation is interrupted, to control subsurfacepressures, to maintain the integrity of the wellbore until the wellsection is cased and cemented, to isolate the fluids from the formationby providing sufficient hydrostatic pressure to prevent the ingress offormation fluids into the wellbore, to cool and lubricate the drillstring and bit, and/or to maximize penetration rate.

In most rotary drilling procedures the drilling fluid takes the form ofa “mud,” i.e., a liquid having solids suspended therein. The solidsfunction to impart desired rheological properties to the drilling fluidand also to increase the density thereof in order to provide a suitablehydrostatic pressure at the bottom of the well. The drilling mud may beeither a water-based or an oil-based mud.

Many wells, especially in oil fields in shale formations (having watersensitivity) and/or deep-water/subsea environments, are drilled withsynthetic/oil-based muds or drilling fluids. Because of the extremelyhigh cost of intervention and high production rates, these wells requirereliable completion techniques that prevent sand production andmaximizes productivity throughout the entire life of the well. One suchtechnique is open-hole gravel packing.

There are two principal techniques used for gravel packing open holes:(1) the alternate path technique and (2) the water packing technique.The latter uses low-viscosity fluids, such as completion brines to carrythe gravel from the surface and deposit it into the annulus between asand-control screen and the wellbore. The alternate path technique, onthe other hand, utilizes viscous carrier fluids; therefore the packingmechanisms of these two techniques are significantly different. Thealternate path technique allows bypassing of any bridges that may formin the annulus, caused by for example high leakoff into the formationdue to filtercake erosion, or exceeding the fracturing pressure, orshale-sloughing/shale-swelling or localized formation collapse on thesand control screens.

In unconsolidated formations, sand control measures are implemented tostabilize formation sand. Common practice for controlling sanddisplacement includes placement of a gravel pack to hold formation sandin place. The gravel pack is typically deposited around a screen. Thegravel pack filters the sand while still allowing formation fluid toflow through the gravel, the screen and a production pipe.

Most of the recently discovered deep-water fields contain a highfraction of shales, which are water-sensitive, although many have beengravel packed with water-based fluids. A very large fraction of themhave been completed with viscous fluids using the alternate pathtechnique. Viscoelastic surfactant (VES) solutions have been the mostwidely used carrier fluid in open hole gravel packing with the alternatepath technique due to their low formation and gravel pack damagecharacteristics, their low drawdown requirements, their capability ofincorporating filtercake cleanup chemicals into the carrier fluid, andtheir low friction pressures.

In wells drilled with synthetic or oil-based muds (often the case forhigh shale fractions and/or deep water wells), three main approacheshave been used for gravel packing. A first approach involvesdisplacement of the entire wellbore to water-based fluids at the end ofdrilling the reservoir section, and subsequently running the sandcontrol screens into the open hole, setting the packer and gravelpacking with a water based fluid. However, as experienced by severaloperators, the problem with this approach is that exposure of reactiveshales to water-based fluids for prolonged time periods can cause shalecollapse or swelling which effectively reduces the wellbore diameter andmakes it impossible to install sand control screens to the target depth(see SPE 89815, SPE 90758) or shale dispersion into the carrier fluidduring gravel packing which can have a significant impact on wellproductivity (Ali et al.—Petroleum Engineer International, March 1999).The success of this approach is therefore heavily dependent on thereactivity of the shales.

One approach subsequently practiced involved installation of apre-drilled (perforated) liner in oil-based mud, then displacement ofthe entire wellbore to water based fluids, subsequent installation ofthe sand control screens to target depth and finally gravel packing witha water based fluid. This approach solved the problem of inability torun the screens to target depth, since shale collapse would occur ontothe pre-drilled liner, and the space inside the predrilled liner wouldbe substantially free of shales, allowing the screens to be installed totarget depth. The problems with this approach were two fold. First, itinvolved two trips (one for predrilled liner installation and anotherfor screen installation), which is costly, particularly in deep waterwhere rig costs are high. Secondly, a smaller size screen had to beinstalled into the wellbore, which in some cases can limit productionrates, and thus increase the costs.

A more recent approach that has been practiced heavily in two deepwaterAngola developments (see SPE 90758 and SPE 107297) and an oilfield inAzerbaijan (see SPE 98146) involved conditioning of the oil based mud bypassing the mud through shaker screens of a certain size (to preventplugging of sand screens), then running the sand screens in conditionedoil based mud, and subsequently displacing the wellbore to water basedfluids and proceeding with gravel packing with a water based carrierfluid (U.S. Pat. Nos. 6,883,608 and 7,373,978). This approach has beensuccessfully used in more than 75 wells to date by two major operators,in conjunction with the alternate path (shunt-tube) screens.

While the above-described methods may be adequate for installing sandscreens and gravel packing in many wells formed in reactiveshale-containing formations, there exists a continuing need forimprovements in the completion fluids used during such methods.

SUMMARY OF INVENTION

In one aspect, embodiments disclosed herein relate to a method of gravelpacking a wellbore in a subterranean formation, the wellbore comprisinga cased section and an uncased section, where the method includespumping into the wellbore a gravel pack composition comprising graveland a carrier fluid comprising an invert emulsion fluid, where theinvert emulsion fluid comprises: an oleaginous external phase; anon-oleaginous internal phase, wherein a ratio of the oleaginousexternal phase and non-oleaginous internal phase is less than 50:50 andan emulsifier stabilizing the oleaginous external phase and thenon-oleaginous internal phase.

In another aspect, embodiments disclosed herein relate to a method ofcompleting a wellbore penetrating a subterranean formation, the wellborecomprising a cased section and an uncased section, where the methodincludes introducing invert emulsion fluid into the cased section of thewellbore, the invert emulsion fluid comprising: an oleaginous externalphase; a non-oleaginous internal phase, wherein a ratio of theoleaginous external phase and non-oleaginous internal phase is less than50:50; and an emulsifier stabilizing the oleaginous external phase andthe non-oleaginous internal phase; and running a liner, sand controlscreen assembly, swell packer assembly, or inflow control device to aselected depth within the uncased section of the wellbore in which theinvert emulsion fluid is located.

Other aspects and advantages of the invention will be apparent from thefollowing description and the appended claims.

BRIEF DESCRIPTION OF DRAWINGS

FIGS. 1A-1D show cross-sectional views of a completion intervaldepicting various stages of a gravel packing operation.

FIG. 2 shows a schematic view of a completion interval depicting agravel packing operation.

FIG. 3 shows the effect of various emulsifiers on electrical stabilitymeasured at various temperatures.

FIG. 4 shows the effect of using various emulsifiers on low shear rateviscosity.

FIG. 5 shows a plot of viscosity versus shear rate for various gravelpack systems.

DETAILED DESCRIPTION

In one aspect, embodiments disclosed herein relate to methods ofcompletion techniques that use invert emulsion fluids during thetechnique(s). More particularly, the present disclosure is directedtoward the use of invert emulsion wellbore fluids in gravel packingand/or installing liners and/or sand control screens in a wellbore thatmay contain reactive shale or clay or in which the use of invertemulsion fluids may otherwise be desirable. As used herein, theexpressions “reactive shale” or “reactive clay” or similar expressionsmay be used interchangeably and refer to those shale or clay materialsthat may swell, crumble, particalize, flake, slough off or otherwisedeteriorate when exposed to aqueous fluids, particularly fresh water.

An invert emulsion is a water-in-oil emulsion, where an oleaginous fluidserves as a continuous phase and a non-oleaginous fluid serves as adiscontinuous phase, the non-oleaginous fluid being stabilized oremulsed in the oleaginous fluid by an emulsifying agent. However, inparticular, the completion techniques of the present disclosure useinvert emulsion fluids having an oil/water ratio of less than 50/50,which may also be referred to as high internal phase ratio (HIPR) invertemulsions or high internal phase emulsions (HIPE). Such HIPR invertemulsions are discussed in more detail below.

As mentioned above, in the drilling of a well, the drilling fluid istypically circulated through the drill string, through the drill bit atthe end of the drill string and up through the annulus between thedrilled wellbore and drill string. The circulated drilling fluid is usedto carry formation rock present as cuttings or drilled solids that areremoved from the wellbore as the drilling fluid is circulated back tothe surface.

In the construction of the well, a casing may be positioned within aportion of the drilled wellbore and cemented into place. The portion ofthe wellbore that is not lined with the casing forms the uncased or openhole section where, in accordance with some embodiments of the presentdisclosure, a sand control screen assembly is placed to facilitategravel packing for controlling the migration and production of formationsand and to stabilize the formation of the open hole section.

Once the wellbore is drilled and the casing cemented into place, thewell may be completed by installing sand screens and gravel packing theopen hole section so that produced fluids from the formation are allowedto flow through the gravel pack and sand screen and may be recoveredthrough the wellbore. The open hole section may be any orientation,including vertical and horizontal hole sections.

After the open hole and cased hole sections are displaced with therespective displacement fluids, the drilling string may be removed fromthe wellbore and the desired sand control screen assembly may be run orlowered to a selected depth within the open hole section of the wellbore. The sand screen assembly may be run or lowered into the wellboreon a tubular member or wash pipe, which is used for conducting fluidsbetween the sand screen and the surface. Running the sand screenassembly to the selected depth may include positioning the sand screenin vertical or non-vertical (horizontal) sections of the well. A packermay be positioned and set in the casing above the sand screen to isolatethe interval being packed. A crossover service tool may also be providedwith the assembly to selectively allow fluids to flow between theannulus formed by the open hole and the screen assembly and the interiorof the tubular member and wash pipe.

With the sand control screen assembly in place, a gravel pack slurrycontaining gravel for forming the gravel pack and a water-based carrierfluid is introduced into the wellbore to facilitate gravel packing ofthe open hole section of wellbore in the annulus surrounding the sandcontrol screen. The gravel pack slurry is typically introduced into thetubular member where it flows to the cross over tool into the annulus ofthe open hole section below the packer and the exterior of the sandcontrol screen. As the gravel settles within the open hole sectionsurrounding the screen, the carrier fluid passes through the screen andinto the interior of the tubular member. The carrier fluid is conductedto the crossover tool and into the annulus between the casing and thetubular member above the packer.

As mentioned above, there are two techniques for gravel packing openholehorizontal wells: “water packing” and viscous-fluid packing or the“alternate path” technique. These techniques have completely differentpacking mechanisms, each having its own advantages and limitations.However, in accordance with the present disclosure, either packingtechnique may use the HIPR invert emulsions of the present disclosure.

Water packing involves gravel packing with a low viscosity carrier fluid(conventionally a completion brine) by a high fluid velocity. Gravel isgenerally added to the fluid at low concentrations and is transported byviscosity. Completion brines are conventionally used as the carrier forsuch technique, as the technique relies on the carrier fluid possessingNewtonian (or near-Newtonian) fluid properties for the annulus to befilled in accordance with this technique. While conventional invertemulsions generally do not have desirable properties (ability to possesslow viscosity with high density: as density increases by increasing theinternal phase volume, the viscosity of the fluid likewise increases)for water packing, the HIPR invert emulsions of the present disclosurepossess both low viscosity and high density.

Referring to FIGS. 1A-1D, a schematic of a horizontal open holecompletion interval of a well that is generally designated 50 beingfilled by a water packing (alpha beta) technique is shown. As shown inFIG. 1A, casing 52 is cemented within a portion of a well 54 proximatethe heel or near end of the horizontal portion of well 54. A work string56 extends through casing 52 and into the open hole completion interval58. A packer assembly 60 is positioned between work string 56 and casing52 at a cross-over assembly 62. Work string 56 includes one or more sandcontrol screen assemblies such as sand control screen assembly 64. Sandcontrol screen assembly 64 includes a base pipe 70 that has a pluralityof openings 72 which allow the flow of fluids therethrough.

Gravel packing the interview is accomplished by delivering fluid slurry84 down work string 56 into cross-over assembly 62. Fluid slurry 84exits cross-over assembly 62 through cross-over ports 90 and isdischarged into horizontal completion interval 58 as indicated by arrows92. In the illustrated embodiment of water packing, fluid slurry 84 thentravels within production interval 58 with portions of the graveldropping out of the slurry and building up on the low side of wellbore54 from the heel to the toe of wellbore 54 as indicated by alpha wavefront 94 of the alpha wave portion of the gravel pack. At the same time,portions of the carrier fluid pass through sand control screen assembly64 and travel through annulus 96 between wash pipe assembly 76 and theinterior of sand control screen assembly 64. These return fluids enterthe far end of wash pipe assembly 76, flow back through wash pipeassembly 76 to cross-over assembly 62, as indicated by arrows 98, andflow into annulus 88 through cross-over ports 100 for return to thesurface.

As shown through the progression of FIGS. 1A-1D, the water packingoperation starts with the alpha wave depositing gravel on the low sideof the wellbore 54 progressing from the near end (heel) to the far end(toe) of the production interval. Gravitational forces dominate this“alpha” wave, so gravel settles until reaching an equilibrium height. Iffluid flow remains above the crucial velocity for particle transport,gravel will move down a horizontal section toward the toe. Once thealpha wave has reached the far end, a second “beta” wave phase asindicated by beta wave front 118 begins to deposit gravel in the highside of the wellbore, on top of the alpha wave deposition, progressingfrom the far (toe) end to the near (heel) end of the productioninterval. The beta wave requires enough fluid velocity to maintainturbulent flow and move gravel along the top of the wellbore annulus.

While the HIPR invert emulsions of the present disclosure may be used inwater packing by alpha and beta waves, the HIPR invert emulsions mayalso be formulated with viscosifiers (such as those disclosed herein) toformulate a viscosified fluid that be used to gravel pack by thealternate path technique. As shown in FIG. 2, the gravel slurry 20 isdiverted to flow through shunt tubes 22 on the outside of the screenassembly 24, which provide an alternative pathway for the slurry 20. Thegravel slurry exits from nozzles (not shown) on the shunt tubes 22 toform a pack 25 in a heel to toe manner. As the gravel settles within theopen hole section 26 surrounding the screen 24, the carrier fluid passesthrough the screen 24 and into the interior of the tubular member 28.The carrier fluid is conducted to the crossover tool 30 and into theannulus between the casing 27 and the tubular member 28 above the packer(not shown).

Under either packing technique, the gravel particles may be ceramics,natural sand or other particulate materials suitable for such purposes.The gravel particles are sized so that they will not pass through thescreen openings. Typical particle sizes in U.S. mesh size may range fromabout 12 mesh (1.68 mm) to about 70 mesh (0.210 mm); however, acombination of different particle sizes may be used. Examples of typicalparticle size combinations for the gravel particles are from about 12/20mesh (1.68 mm/0.841 mm), 16/20 mesh (1.19 mm/0.841 mm), 16/30 mesh (1.19mm/0.595 mm), 20/40 mesh (0.841 mm/0.420 mm), 30/50 mesh (0.595 mm/0297mm), 40/60 mesh (0.420 mm/0.250 mm) and 40/70 mesh (0.420 mm/0.210 mm).The gravel particles may be coated with a resin to facilitate binding ofthe particles together. The resin-coated particles may be pre-cured ormay cure in situ, such as by an overflush of a chemical binding agent orby elevated formation temperatures.

In addition to (or instead of) using the HIPR invert emulsions as acarrier fluid for gravel packing, in accordance with the presentdisclosure, the HIPR invert emulsions may also be used during theplacement of sand control screens and/or liners, as well as othercompletion equipment.

The HIPR invert emulsion fluids may be used with almost any type ofliner or and/or sand control screen assembly. These may includepre-holed liners, slotted, liners, wire-wrapped screens, prepackedscreens, direct-wrapped sand screens, mesh screens, premium-typescreens, etc. Premium-type screens typically consist of multi-layers ofmesh woven media along with a drainage layer. Premium-type screens donot have a well defined screen opening size. In contrast, wire wrapscreens consist of wire uniformly wrapped around a perforated base pipe.The wire wrap screens have a relatively uniform screen opening definedas gauge opening. Further, as described above, the sand control screenassembly may also include those with alternate flow paths or shunttubes. Moreover, screen assemblies may also include those that includediverter valves for diverting fluid returns through a shorter pathway,preventing pressure build up during the gravel packing process. Othercompletion equipment with which the HIPR invert emulsions may be usedincludes packer assemblies (including swell packer assemblies), whichseparate upper annuli from lower production equipment in a well, orinflow control devices, which limit the inflow of fluids into theproduction tubing) The particular type of equipment is of no limitationon the present disclosure; rather, the HIPR invert emulsions may be usedwith any type of equipment while the equipment is being run in the holeor during subsequent completion operations prior to the well being putinto production. Further, depending on the arrangement, one or more ofsuch completion equipment may be used in combination with each other.

In accordance with embodiments of the present disclosure, prior toinstalling sand control screens (using the HIPR fluids or not) and/orgravel packing (using the HIPR fluids or not), the drilling fluid mayoptionally be first displaced from the open hole section to adisplacement fluid, and a second fluid may optionally be used todisplace the fluid in a cased hole section. Displacement of the drillingfluids from the open hole section may be carried out by introducing thedisplacement fluid into the wellbore by passing the displacement fluidthrough the tubular drill string to the open hole section. As thedisplacement fluid is pumped through the drill string, the drillingfluids in the open hole section are carried upward through the annulusformed by the casing and the drill string. In a particular embodiment,if the formation includes reactive clays, the displacement fluid for theopen hole section may include the HIPR invert emulsions to help maintainthe integrity of the open hole section containing reactive shales orclays that could otherwise be damaged if water-based fluids were used todisplace the drilling fluids. In certain embodiments, the volume offirst displacement fluid used may be sufficient to displace the openhole section plus the cased hole section up to the packer setting depth.

When a sufficient volume of the first displacement fluid is introducedinto the wellbore to displace the drilling fluid from the open holesection of the wellbore, a second displacement fluid (optionally thesame or different than the first) is used to displace at least a portionor all of the cased hole section of the wellbore. In certainembodiments, the volume of the second fluid may be sufficient todisplace the entire cased section above the packer setting depth. Thismay be carried out by raising the end of the tubular drill string sothat it is positioned within the cased hole section above the open holesection so that the second displacement fluid is discharged from the endof the drill string into the cased hole section.

Sand control screens and/or liners, or other completion equipment suchas packer assemblies (including swell packer assemblies) or inflowcontrol devices (limiting the inflow of fluids into the productiontubing) are then run to target depth, which may optionally be in thepresence of the HIPR invert emulsions of the present disclosure. Thesand control screen may be a standalone sand screen or an expandablesand screen. After the sand control screen is installed, the well may begravel packed with a HIPR invert emulsion fluid, as disclosed herein.Further, one of ordinary skill in the art would appreciate that one ormore of such completion equipment may be used in combination.

HIPR Invert Emulsion Fluids

As discussed above, the methods of the present disclosure use invertemulsion fluids having an oil/water ratio of less than 50/50, which mayalso be referred to as HIPR invert emulsions. The oil/water ratio ininvert emulsion fluids conventionally used in the field is in the rangeof 65/45 to 85/15. Several factors have conventionally dictated suchranges, including: the concentration of solids in the mud to provide thedesired mud weight (solids laden muds must have a high O/W ratio to keepthe solids oil wet and dispersed) and the high viscosities oftenexperienced upon increase of the internal aqueous phase (due to thegreater concentration of the dispersed internal phase).

The instability of the emulsions may be explained by examining theprinciples of colloid chemistry. The stability of a colloidal dispersion(emulsion for a liquid-liquid dispersion) is determined by the behaviorof the surface of the particle via its surface charge and short-rangeattractive van der Waals forces. Electrostatic repulsion preventsdispersed particles from combining into their most thermodynamicallystable state of aggregration into the macroscopic form, thus renderingthe dispersions metastable. Emulsions are metastable systems for whichphase separation of the oil and water phases represents to the moststable thermodynamic state due to the addition of a surfactant to reducethe interfacial energy between oil and water.

Oil-in-water emulsions are typically stabilized by both electrostaticstabilization (electric double layer between the two phases) and stericstabilization (van der Waals repulsive forces), whereas invert emulsions(water-in-oil) are typically stabilized by only steric stabilization.Because only one mechanism can be used to stabilize an invert emulsion,invert emulsions are generally more difficult to stabilize, particularlyat higher levels of the internal phase, and often experience highlyviscous fluids.

Thus, embodiments of the present disclosure relate to invert emulsionfluids having a high internal phase concentration (<50/50 O/W), whichare stabilized by an emulsifying agent without significant increases inviscosity. Additional by virtue of the greater internal phaseconcentration, weight may be provided to the fluid partly through theinherent weight of the aqueous or other internal phase, thus minimizingthe total solid content.

As the internal aqueous phase of a given fluid system increases, theviscosity and rheological profile of the fluid also increases due to thegreater concentration of the dispersed internal phase. However, theinvert emulsion fluids of the present disclosure may possess rheologicalprofiles more similar to fluids having a lower internal phaseconcentration, i.e., >50/50 O/W. In particular, in accordance withembodiments of the present disclosure, the fluids may possess a highshear viscosity of less than 200 at 600 rpm, and a low shear viscosityof less than 40 at 6 and 3 rpm, and less than 20 at 6 and 3 rpm inparticular embodiments (all of which are measured using a Fann 35Viscometer from Fann Instrument Company (Houston, Tex.) at 120° F.).

The HIPR fluid may also possess internal aqueous phase that is stablyemulsed within the external oleaginous phase. Specifically, uponapplication of an electric field to an invert emulsion fluid, theemulsified non-oleaginous phase, which possesses charge, will migrate toone of the electrodes used to generate the electric field. Theincorporation of emulsifiers in the invert emulsion fluid stabilizes theemulsion and results in a slowing of the migration rate and/or increasedvoltage for breakage of the emulsion. Thus, an electrical stability (ES)test, specified by the American Petroleum Institute at API RecommendedPractice 13B-2, Third Edition (February 1998), is often used todetermine the stability of the emulsion. ES is determined by applying avoltage-ramped, sinusoidal electrical signal across a probe (consistingof a pair of parallel flat-plate electrodes) immersed in the mud. Theresulting current remains low until a threshold voltage is reached,whereupon the current rises very rapidly. This threshold voltage isreferred to as the ES (“the API ES”) of the mud and is defined as thevoltage in peak volts-measured when the current reaches 61 μA. The testis performed by inserting the ES probe into a cup of 120° F. [48.9° C.]mud applying an increasing voltage (from 0 to 2000 volts) across anelectrode gap in the probe. The higher the ES voltage measured for thefluid, the stronger or harder to break would be the emulsion createdwith the fluid, and the more stable the emulsion is. Thus, the presentdisclosure relates to invert emulsion fluids having a high internalphase ratio but that also have an electrical stability of at least 50 vand at least 100 v or 150 v in more particular embodiments.

Further, the present disclosure also relates to fluids having a highinternal phase ratio wherein the emulsion droplet size is smaller ascompared to conventional emulsion droplets. For example, thenon-oleaginous phase distributed in the oleaginous phase may have anaverage diameter in the range of 0.5 to 5 microns in one embodiment, andin the range of 1 to 3 microns in a more particular embodiment. Thedroplet size distribution may generally such that at least 90% of thediameters are within 20% or especially 10% of the average diameter. Inother embodiments, there may be a multimodal distribution. This dropletsize may be approximately one-third to one-fourth the size of emulsiondroplets formed using conventional emulsifiers. In a particularembodiment, the emulsion droplets may be smaller than the solidweighting agents used in the fluids.

One example of an emulsifying agent that may stabilize the emulsion ofthe aqueous or non-oleaginous fluid within the oleaginous fluid, wherethe non-oleaginous fluid is present in a volume amount that is more thanthe non-oleaginous fluid, is an alkoxylated ether acid. In embodiment ofan alkoxylated ether acid is an alkoxylated fatty alcohol terminatedwith an carboxylic acid, represented by the following formula:

where R is C₆-C₂₄ or —C(O)R³ (where R³ is C₁₀-C₂₂), R¹ is H or C₁-C₄, R²is C₁-C₅ and n may range from 1 to 20. Such compound may be formed bythe reaction of an alcohol with a polyether (such as poly(ethyleneoxide), poly(propylene oxide), poly(butylene oxide), or copolymers ofethylene oxide, propylene oxide, and/or butylene oxide) to form analkoxylated alcohol. The alkoxylated alcohol may then be reacted with anα-halocarboxylic acid (such as chloroacetic acid, chloropropionic acid,etc.) to form the alkoxylated ether acid. In a particular embodiment,the selection of n may be based on the lipophilicity of the compound andthe type of polyether used in the alkoxylation. In some particularembodiments, where R¹ is H (formed from reaction with poly(ethyleneoxide)), n may be 2 to 10 (between 2 and 5 in some embodiments andbetween 2 and 4 in more particular embodiments). In other particularembodiments, where R¹ is —CH₃, n may range up to 20 (and up to 15 inother embodiments). Further, selection of R (or R³) and R² may alsodepend on based on the hydrophilicity of the compound due to the extentof polyetherification (i.e., number of n). In selecting each R (or R³),R¹, R², and n, the relative hydrophilicity and lipophilicity contributedby each selection may be considered so that the desired HLB value may beachieved. Further, while this emulsifier may be particularly suitablefor use in creating a fluid having a greater than 50% non-oleaginousinternal phase, embodiments of the present disclosure may also includeinvert emulsion fluids formed with such emulsifier at lower internalphase amounts.

The term “HLB” (Hydrophilic Lipophilic Balance) refers to the ratio ofthe hydrophilicity of the polar groups of the surface-active moleculesto the hydrophobicity of the lipophilic part of the same molecules. Oneskilled in the art would appreciate that an HLB value may be calculatedby considering the molecular weight contributions of the respectivehydrophilic and lipophilic portions and taking the ratio thereof(divided by 5). Generally, the Bancroft rule applies to the behavior ofemulsions: emulsifiers and emulsifying particles tend to promotedispersion of the phase in which they do not dissolve very well; forexample, a compound that dissolves better in water than in oil tends toform oil-in-water emulsions (that is they promote the dispersion of oildroplets throughout a continuous phase of water). Emulsifiers aretypically amphiphilic. That is, they possess both a hydrophilic portionand a hydrophobic portion. The chemistry and strength of the hydrophilicpolar group compared with those of the lipophilic nonpolar groupdetermine whether the emulsion forms as an oil-in-water or water-in-oilemulsion. In particular, emulsifiers may be evaluated based on their HLBvalue. Generally, to form a water-in-oil emulsion, an emulsifier (or amixture of emulsifiers) having a low HLB, such as between 3 and 8, maybe desirable. In a particular embodiment, the HLB value of theemulsifier may range from 4 to 6.

In particular embodiments, the emulsifier may be used in an amountranging from 1 to 15 pounds per barrel, and from 2 to 10 pounds perbarrel, in other particular embodiments.

In addition to the emulsifying agent that stabilizes the oleaginouscontinuous phase and non-oleaginous discontinuous phase, the wellborefluids may also include, for example, weighting agents.

Weighting agents or density materials (other than the inherent weightprovided by the internal aqueous phase) suitable for use the fluidsdisclosed herein may include barite, galena, hematite, magnetite, ironoxides, illmenite, siderite, celestite, dolomite, calcite, and the like.The quantity of such material added, if any, depends upon the desireddensity of the final composition. Typically, weighting material may beadded to result in a fluid density of up to about 24 pounds per gallon(but up to 21 pounds per gallon or up to 19 pounds per gallon in otherparticular embodiments). Additionally, it is also within the scope ofthe present disclosure that the fluid may also be weighted up usingsalts (such as in the non-oleaginous fluid (often aqueous fluid)discussed below). One having ordinary skill in the art would recognizethat selection of a particular material may depend largely on thedensity of the material as typically, the lowest wellbore fluidviscosity at any particular density is obtained by using the highestdensity particles.

The oleaginous fluid may be a liquid and more preferably is a natural orsynthetic oil and more preferably the oleaginous fluid is selected fromthe group including diesel oil; mineral oil; a synthetic oil, such ashydrogenated and unhydrogenated olefins including polyalpha olefins,linear and branch olefins and the like, polydiorganosiloxanes,siloxanes, or organosiloxanes, esters of fatty acids, specificallystraight chain, branched and cyclical alkyl ethers of fatty acids,mixtures thereof and similar compounds known to one of skill in the art;and mixtures thereof. In a particular embodiment, the fluids may beformulated using diesel oil or a synthetic oil as the external phase.The concentration of the oleaginous fluid should be sufficient so thatan invert emulsion forms and may be less than about 50% by volume of theinvert emulsion. In one embodiment the amount of oleaginous fluid isfrom about 50% to about 20% by volume and more preferably about 40% toabout 20% by volume of the invert emulsion fluid. The oleaginous fluidin one embodiment may include at least 5% by volume of a materialselected from the group including esters, ethers, acetals,dialkylcarbonates, hydrocarbons, and combinations thereof.

The non-oleaginous fluid used in the formulation of the invert emulsionfluid disclosed herein is a liquid and preferably is an aqueous liquid.More preferably, the non-oleaginous liquid may be selected from thegroup including sea water, a brine containing organic and/or inorganicdissolved salts, liquids containing water-miscible organic compounds andcombinations thereof. For example, the aqueous fluid may be formulatedwith mixtures of desired salts in fresh water. Such salts may include,but are not limited to alkali metal chlorides, hydroxides, orcarboxylates, for example. In various embodiments of the drilling fluiddisclosed herein, the brine may include seawater, aqueous solutionswherein the salt concentration is less than that of sea water, oraqueous solutions wherein the salt concentration is greater than that ofsea water. Salts that may be found in seawater include, but are notlimited to, sodium, calcium, aluminum, magnesium, potassium, strontium,and lithium, salts of chlorides, bromides, carbonates, iodides,chlorates, bromates, formates, nitrates, oxides, phosphates, sulfates,silicates, and fluorides. Salts that may be incorporated in a givenbrine include any one or more of those present in natural seawater orany other organic or inorganic dissolved salts. Additionally, brinesthat may be used in the drilling fluids disclosed herein may be naturalor synthetic, with synthetic brines tending to be much simpler inconstitution. In one embodiment, the density of the drilling fluid maybe controlled by increasing the salt concentration in the brine (up tosaturation). In a particular embodiment, a brine may include halide orcarboxylate salts of mono- or divalent cations of metals, such ascesium, potassium, calcium, zinc, and/or sodium.

The amount of the non-oleaginous fluid is typically less than thetheoretical limit needed for forming an invert emulsion. Thus in oneembodiment the amount of non-oleaginous fluid is more than about 50% byvolume and preferably from about 50% to about 80% by volume. In anotherembodiment, the non-oleaginous fluid is preferably from about 60% toabout 80% by volume of the invert emulsion fluid.

Conventional methods can be used to prepare the drilling fluidsdisclosed herein in a manner analogous to those normally used, toprepare conventional oil-based drilling fluids. In one embodiment, adesired quantity of oleaginous fluid such as a base oil and a suitableamount of a surfactant are mixed together and the remaining componentsare added sequentially with continuous mixing. An invert emulsion mayalso be formed by vigorously agitating, mixing or shearing theoleaginous fluid and the non-oleaginous fluid.

Other additives that may be included in the wellbore fluids disclosedherein include for example, wetting agents, organophilic clays,viscosifiers, surfactants, dispersants, interfacial tension reducers, pHbuffers, mutual solvents, thinners, thinning agents and cleaning agents.The addition of such agents should be well known to one of ordinaryskill in the art of formulating drilling fluids and muds.

Wetting agents that may be suitable for use in the fluids disclosedherein include crude tall oil, oxidized crude tall oil, surfactants,organic phosphate esters, modified imidazolines and amidoamines, alkylaromatic sulfates and sulfonates, and the like, and combinations orderivatives of these. However, when used with the invert emulsion fluid,the use of fatty acid wetting agents should be minimized so as to notadversely affect the reversibility of the invert emulsion disclosedherein. FAZE-WET™, VERSACOAT™, SUREWET™, VERSAWET™, and VERSAWET™ NS areexamples of commercially available wetting agents manufactured anddistributed by M-I L.L.C. that may be used in the fluids disclosedherein. Silwet L-77, L-7001, L7605, and L-7622 are examples ofcommercially available surfactants and wetting agents manufactured anddistributed by General Electric Company (Wilton, Conn.).

Conventional viscosifying agents that may be used in the fluidsdisclosed herein include organophilic clays, amine treated clays, oilsoluble polymers, polyamide resins, polycarboxylic acids, and soaps,particularly during gravel packing by the alternate path technique(viscous fluid packing). The amount of viscosifier used in thecomposition can vary upon the end use of the composition. However,normally about 0.1% to 6% by weight range is sufficient for mostapplications. VG-69™ and VG-PLU™ are organoclay materials distributed byM-I, L.L.C., Houston, Tex., and VERSA-HRP™ is a polyamide resin materialmanufactured and distributed by M-I, L.L.C., that may be used in thefluids disclosed herein. While such viscosifiers may be particularlyuseful during viscous fluid packing, they viscosifiers may also beincorporated into the fluid formulation for other completion operationsas well.

Additionally, lime or other alkaline materials are typically added toconventional invert emulsion drilling fluids and muds to maintain areserve alkalinity.

The fluids disclosed herein are especially useful in the drilling,completion and working over of subterranean oil and gas wells. Inparticular the fluids disclosed herein may find use in formulatingdrilling muds and completion fluids that allow for the easy and quickremoval of the filter cake. Such muds and fluids are especially usefulin the drilling of horizontal wells into hydrocarbon bearing formations.

In various embodiments, methods of drilling a subterranean hole with aninvert emulsion drilling fluid may comprise mixing an oleaginous fluid,a non-oleaginous fluid, an emulsifier, such as those described above,and in the ratios described above, to form an invert emulsion; anddrilling the subterranean hole using this invert emulsion as thedrilling fluid. The fluid may be pumped down to the bottom of the wellthrough a drill pipe, where the fluid emerges through ports in thedrilling bit, for example. In one embodiment, the fluid may be used inconjunction with any drilling operation, which may include, for example,vertical drilling, extended reach drilling, and directional drilling.One skilled in the art would recognize that oil-based drilling muds maybe prepared with a large variety of formulations. Specific formulationsmay depend on the state of drilling a well at a particular time, forexample, depending on the depth and/or the composition of the formation.

EXAMPLE

The following examples were used to test the stability and rheologicalproperties of a high internal phase ratio invert emulsion, such as thosedescribed in the present disclosure.

Example 1

Various high internal phase ratio invert emulsions were formulatedhaving the following components, as shown below in Table 1A and 1B.Specifically, the components include a C16-C18 internal olefin as thebase oil, various brines having densities as described below) SUREWET®,a secondary emulsifier available from M-I L.L.C. (Houston, Tex.); andEMI-2184, an alkoxylated ether acid emulsifier available from M-I L.L.C.(Houston, Tex.). Samples 1-3 show the lack of effect of brine type onemulsion stability, while samples 4-6 investigate the effect ofincreasing salt density on the emulsion stability. Samples 7-9investigate the effect of the amount of emulsifier on a 30/70 O/W ratio,and Samples 10-12 investigate the effect of the O/W ratio (50/50, 40/60,and 30/70).

TABLE 1A Components 1 2 3 4 5 6 IO C16-C18 (mL) 72 72 72 92 92 92 CaCl₂brine (mL) 287 — — 233 — — (11.2 ppg) (11.6 ppg) K-formate brine (mL) —287 — — 233 — (11.2 ppg) (13.7 ppg) CaBr₂ brine (mL) — — 287 — — 233(11.2 ppg) (14.2 ppg) SUREWET ® (g) 2 2 2 2 2 2 EMI-2184 (g) 9 9 9 9 9 9Lime (g) 2 2 2 2 2 2 Barite (g) 47 47 47 47 47 47

TABLE 1B Components 7 8 9 10 (50/50) 11 (40/60) 12 (30/70) IO C16-C18(mL) 92 92 92 119 96 72 25% CaCl₂ brine 233 233 233 53 64 76 (mL)SUREWET ® (g) 2 2 2 2 2 2 EMI-2184 (g) 2 4 6 9 9 9 Lime (g) 2 2 2 2 2 2Barite (g) 47 47 47 85 85 85

The invert emulsion fluids shown in Table 1 were heat aged at thetemperatures shown below in Table 2A and 2B by hot rolling for 16 hours,and the rheological properties of the various mud formulations weredetermined using a Fann Model 35 Viscometer, available from FannInstrument Company. The fluid exhibited the following properties, asshown below in Table 2A and 2B.

TABLE 2A Sample Nos. 1 2 3 4 5 6 Heat Aging 150 300 150 300 150 300 150250 150 250 150 250 (° F.) 600 RPM 120 139 156 185 124 132 181 163 145163 Direct — 300 RPM 75 88 99 120 77 84 114 101 90 101 Emul — 200 RPM 5768 74 94 57 59 89 76 67 76 — — 100 RPM 35 42 47 60 35 41 57 46 41 46 — — 6 RPM 8 15 11 16 8 9 12 10 9 11 — —  3 RPM 6 12 10 14 7 7 9 8 7 9 — —10 s gel 7 8 10 10 7 7 10 9 8 10 — — 10m gel 7 8 11 12 8 7 10 8 9 10 — —PV (cP) 45 51 57 65 47 48 67 62 55 62 — — YP (lb/100 ft²) 30 37 42 55 3036 47 39 35 39 — — ES (v) 198 152 148 160 207 120 164 94 35 54 6 —

TABLE 2B Sample Nos. 7 8 9 10 11 12 Heat Aging (° F.) 150 250 150 250150 250 150 150 150 300 600 RPM 270 196 134 153 153 160 52 91 172 150300 RPM 182 126 84 98 98 101 28 53 103 89 200 RPM 139 96 64 76 76 78 1936 75 64 100 RPM 94 60 41 46 46 49 11 20 46 38  6 RPM 28 12 8 8 10 11 35 9 7  3 RPM 21 10 6 7 8 9 2 4 7 6 10 s gel 20 10 7 7 9 8 3 5 7 7 10mgel 21 10 8 8 9 9 4 6 8 8 PV (cP) 88 70 50 55 55 59 24 38 69 61 YP(lb/100 ft²) 94 56 34 53 43 42 4 15 34 28 ES (v) 25 55 70 117 103 201232 207 130 220

A high internal phase ratio invert emulsion fluid according to thepresent disclosure was formed and compared to an invert emulsion fluidat the same phase ratio, but with a conventional emulsifier, SUREMUL®,available from M-I L.L.C. (Houston, Tex.). The sample and comparativesample were formulated having the following components, as shown belowin Table 3.

TABLE 3 Components 13 CS1 IO C16-C18 (mL) 70.61 70.61 CaCl₂ (g) 74 74Water 208 208 SUREMUL ® (g) — 9 SUREWET ® (g) 2 2 EMI-2184 (g) 9 — Lime(g) 2 2 Barite (g) 75.75 75.75

The invert emulsion fluids shown in Table 3 were heat aged at 150° F. byhot rolling for 16 hours, and the rheological properties of the variousmud formulations were determined at 120° F. using a Fann Model 35Viscometer, available from Fann Instrument Company. The fluid exhibitedthe following properties, as shown below in Table 4.

TABLE 4 13 CS1 600 RPM 171 >300 300 RPM 106 210 6 RPM 11 41 3 RPM 9 3310 s gel 9 31 10 m gel 10 34 PV (cP) 65 N/A YP (lb/100 ft²) 41 N/A ES(v) 287 110

Example 2

Various high internal phase ratio invert emulsions were formulatedhaving the following components, as shown below in Table 5.Specifically, the components include a C16-C18 internal olefin as thebase oil, various brines having densities as described below) SUREWET®,a secondary emulsifier available from M-I L.L.C. (Houston, Tex.); andDANOX-20, DANOX-21, and DANOX-22, alkoxylated ether carboxylic acidemulsifiers available from Kao Corporation (Tokyo, Japan). DANOX-20,DANOX-21, and DANOX-22 possess the same chemistry with differing amountof ethoxylation (and thus molecular weight and HLB).

TABLE 5 Components 13 14 15 IO C16-C18 (mL) 72 72 72 CaCl₂ brine (mL) 7676 76 Water 212 212 212 SUREWET ® (g) 2 2 2 DANOX-20 (g) 9 — — DANOX-21(g) — 9 — DANOX-21 (g) — — 9 Lime (g) 2 2 2 Barite (g) 47 47 47

The invert emulsion fluids shown in Table 5 were heat aged at thetemperatures shown below in Table 6 by hot rolling for 16 hours, and therheological properties of the various mud formulations were determinedusing a Fann Model 35 Viscometer, available from Fann InstrumentCompany. The fluid exhibited the following properties, as shown below inTable 6.

TABLE 2A Sample Nos. 13 14 15 Heat Aging (° F.) 150 250 150 250 150 250600 RPM 143 167 134 173 136 160 300 RPM 89 102 82 105 85 99 200 RPM 67 —61 — 64 — 100 RPM 42 — 36 — 38 —  6 RPM 9 11 7 10 8 10  3 RPM 7 8 6 7 78 10 s gel 7 8 6 8 7 8 10m gel 7 9 6 8 8 9 PV (cP) 54 65 52 68 51 61 YP(lb/100 ft²) 35 37 30 37 34 38 ES (v) 185 200 150 171 167 181

Example 3

A simple laboratory assessment was undertaken to assess the ability toachieve Newtonian properties when formulating an invert system withrelatively high internal aqueous phase. For this assessment alow-toxicity mineral oil was used to achieve an arbitrary density of 9.0lb/gal in a 50/50 O/W ratio HIPR fluid. Several comparative fluids wereprepared using two different amido-amines at arbitrary concentrations inan attempt to achieve a Newtonian regime at a 50/50 O/W ratio. Theinvert fluids were prepared by first blending the emulsifier into theselected base fluid followed with the addition of lime. The internalphase, CaCl₂ brine, was added last. Due to the relatively high waterratio, the systems were vigorously stirred at the highest rateattainable while minimizing entrainment of air to ensure completedispersion and to ensure emulsion stability and to mitigateinconsistency with respect to preparation. The HIPR formulation is shownin Table 3.

TABLE 3 9.0-lb/gal HIPR Formulation for a Water-Pack Fluid Productslb/bbl Base Oil 128 EMI-2184  8-10 Lime 2-4 CaCl₂ Brine 239

After mixing, the rheology was measured using a standard Fann 35 at 120°F. In addition, the low-shear-rate viscosity (LSRV) and the electricalstability (ES) were measured. The initial properties for the HIPR fluidare shown in Table 4, below.

TABLE 4 Properties of a 9.0-lb/gal HIPR Water-Pack Fluid at 120° F.(48.89° C.) Property Value O/W Ratio 50/50 ES (V) 87 PV/YP (cP/lb/100ft²) 37/9  6/3-rpm Readings 3/2 Density 9.0 lb/gal (SG of 1.08) n/Kvalue (Herschel Buckley) 0.69/177

The ES and LSRV laboratory measurements were acquired to assess low-endviscosity and emulsion stability. The ES was measured to confirm that aninvert emulsion was apparent. As it was surmised that a lower viscositywould promote the ability to effectively deposit the desired alpha andbeta waves/dunes, the measurement and subsequent deficient LSRV wouldconfirm this aspect. Solids suspension of biopolymer fluids has beencorrelated directly to LSRV measurements at 0.06 sec⁻¹ (0.3 rpm). Thus,this method was employed for these invert fluids. Elevated viscosity,especially the low-end, is indicative of the ability to suspendparticles (e.g., gravel) thus mitigating the ability to effectivelydeposit especially when the velocity of the packing fluid is reduced.

Several fluids were compared to fluids formulated with EMI-2184 (at 7pounds per barrel (ppb) and 10 ppb), an alkoxylated ether acidemulsifier, to form a HIPR fluid. The comparative fluids were formulatedwith VERSACOAT HF (at 2 ppb, 3 ppb and 6 ppb) an amido-amine, and ONEMUL(at 4 ppb and 7 ppb), an amido-amine with an added surfactant, both ofwhich are available from M-I SWACO (Houston, Tex.). The fluids wereformulated as shown in Table 5 below.

TABLE 5 9.0-lb/gal Formulation for a Water- Pack Fluid Products lb/bblBase Oil 128 Emulsifier Varies Lime 2-4 CaCl₂ Brine 239

The first assessment (FIG. 3) compares the ES values for the fluidformulations as shown in Table 5, including an HIPR invert emulsionformed with the HIPR emulsifier as well as comparative fluids formulatedwith amido-amine surfactants at the various concentrations mentionedabove. The ES was measured at four temperatures ranging from 40 to 150°F. The two fluids formulated with the HIPR emulsifier or the amido-amineplus a surfactant exhibited more consistent ES across all temperaturesas well as the ability to manage the ES value with a change inconcentration. From this data, the fluids emulsified with an amido-aminetype emulsifier provided relatively greater ES values across alltemperatures. Even with decreased concentration, this emulsifierprovided elevated ES values. For these fluids, laboratory observationsshowed a low ES is indicative of less viscosity as would be expectedwhen solids are not introduced.

To further assess the ability to create a HIPR water packing fluid withO/W ratio of 50/50 while mitigating viscosity, these fluids wereevaluated using a Brookfield viscometer. FIG. 4 shows a comparison ofthe LSRV values at 0.3 rpm. These values show that the amido-amine andamido-amine plus surfactant generated more viscosity at this shear ratethan the HIPR emulsifier, almost 9.5 to 11 times more.

The fluids were also subjected to a wettability evaluation. This testwas performed to confirm that a system formulated with the HIPRemulsifier would continue to function as an emulsion thus mitigating therelatively large water or brine fraction's contact with eitherwater-sensitive shale or the target formation rock. The HIPR fluids wassubjected to a simple wettability test before and after adding1.0-lb/gal proppant to a fluid prepared as documented above in Table 4.This fluid was prepared using 7 lb/bbl of HIPR emulsifier. Afterblending and aging for 16 hours at 150° F., a small portion or volumewas extracted using a plastic pipette and then placed into a beaker oftap water. A stable emulsion or invert upon contact with water willyield a sphere as it seeks to attain the smallest possible surface area.In contrast, if the emulsion or invert exhibits a cloudy dispersion orstingy texture, this indicates poor or unstable emulsified fluid. Thefluid prepared with the HIPR emulsifier exhibited sphere-like dropletsand is indicative of a stable emulsion with a measured ES ofapproximately 40 to 80 volts.

It is surmised that this fluid would maintain a stable emulsion in awellbore of similar bottomhole temperature while providing an oil-wetenvironment as opposed to water-wetting (potentially damaging the targetreservoir rock or shale rock). The authors surmise that the HIPRemulsifier's ability oil-wet as well as maintaining a stable ES incombination with low viscosity and LSRV would provide an alternative forwater-packing where shale rock is prevalent, thus lowering the risk forpremature sand-out.

To further assess the stability of a fluid formulated with the HIPRemulsifier, static aging tests were performed. Again the fluids werecompared to the conventional amido-amine plus surfactant at 4 and7-lb/bbl concentrations. All samples were statically aged at threedifferent temperatures to simulate a wellbore environment. Before heataging, all fluids exhibited a stable invert emulsion, as expected, withno separation apparent. After static aging, the fluid formulated with anamido amine type emulsifier showed relatively more syneresis or phaseseparation, visually up to 15 vol %, whereas, in the fluids formulatedwith an HIPR emulsifier, no separation is apparent. However, thesyneresis was readily resolved for the amido-amine fluid with simpleagitation as would be typical for any properly formulated invert. Theability of the HIPR emulsifier to mitigate syneresis may provebeneficial for pre-bending and even mitigating separation in thewellbore during static conditions.

As a final comparison, the rheology was measured at 120° F. for theprevious HIPR fluids plus an invert system with 4-lb/bbl amido-amineplus surfactant. This data was again plotted as the natural log ofviscosity (cP) versus the natural log of the shear rate for comparison(FIG. 5). In addition, several conventional systems were included forreference. The HIPR fluids formulated with 50/50 and 40/60 O/W ratios,exhibited relatively similar slopes, as well as exhibited lowerviscosity than a conventional amido amine fluid. The slopes of the HIPRfluids exhibited a flatter profile versus an HEC slicked system, thusapproaching a more Newtonian regime.

Example 4

For this assessment, laboratory tests were conducted using the HIPRemulsifier to formulate fluids to a density of 10.5 lb/gal. Threedifferent completion brines—11.8-lb/gal sodium bromide, 11.5-lb/galcalcium chloride, and 11.7-lb/gal potassium formate—were incorporated toassess their compatibility with the HIPR emulsifier. Thus, the O/Wratios varied from 23/77 to 34/66 to attain the target density. Thesesystems were blended in the same manner as described before. Therheology is shown in Table 6 and was measured at a temperature of 85° F.to assess surface conditions.

TABLE 6 10.5-lb/gal HIPR Screen Running Fluids Rheology Measured at 120°F. Temperature 85° F. 85° F. 85° F. Brine Type CaCl₂ NaBr KCOOH O/WRatio 23/77 29/71 34/66 600-rpm Reading 245 205   300+ 300-rpm Reading152 132 240 200-rpm Reading 116 102 195 100-rpm Reading 72 67 140  6-rpmReading 10 16  49  3-rpm Reading 6 12  42  10-sec Gel (lb/100 ft²) 7 12 39  10-min Gel (lb/100 ft²) 6 11  39 PV (cP) 93 73 n/a YP (lb/100 ft²)59 59 n/a

From this data, the use of these brines parallels the rheology measuredin Table 2 above (for Samples 1-3). These results indicate thatpotassium formate brine requires less concentration of the HIPRemulsifier. The fluids formulated with CaCl₂ and NaBr exhibit rheologyconducive for displacing/running a sand control screen or liner.

Advantageously, embodiments of the present disclosure may provide invertemulsion fluids having a high internal phase concentration (<50/50 O/W),which are stabilized by an emulsifying agent without significantincreases in viscosity, making the fluids particularly suitable for usein open hole completion operations, as a displacement fluid, for runningliners and/or sand control screens, as well as gravel packing by withalpha and beta waves or by an alternate path technique. Additionally byvirtue of the greater internal phase concentration, weight may beprovided to the fluid partly through the inherent weight of the aqueousor other internal phase, thus minimizing the total solid content, whichis particularly desirable for completion operations in which a no solidscontent is often desired. Further, such fluids may be particularlydesirable for use in open hole wells exposed to reactive shales, byminimizing the potential contact of such reactive shales with water. TheHIPR invert emulsions may make it practical for a well to be drilled andcompleted only with oil-based fluids, avoiding contact of the formationwith brines, which can have a negative effect on the production of thewells.

While the invention has been described with respect to a limited numberof embodiments, those skilled in the art, having benefit of thisdisclosure, will appreciate that other embodiments can be devised whichdo not depart from the scope of the invention as disclosed herein.Accordingly, the scope of the invention should be limited only by theattached claims.

What is claimed is:
 1. A method of completing a wellbore penetrating asubterranean formation, the wellbore comprising a cased section and anuncased section, the method comprising: introducing invert emulsionfluid into the uncased section of the wellbore, the invert emulsionfluid comprising: an oleaginous external phase; a non-oleaginousinternal phase, wherein a ratio of the oleaginous external phase andnon-oleaginous internal phase is less than 50:50; and an emulsifierstabilizing the oleaginous external phase and the non-oleaginousinternal phase; and running a liner, sand control screen assembly, swellpacker assembly, or inflow control device to a selected depth within theuncased section of the wellbore in which the invert emulsion fluid islocated; wherein the emulsifier is an alkoxylated ether acid.
 2. Themethod of claim 1, further comprising introducing a gravel pack slurrycontaining gravel and an invert emulsion carrier fluid into thewellbore.
 3. The method of claim 1, wherein introducing the invertemulsion fluid into the uncased section of the wellbore displaces adrilling fluids from the uncased section of the wellbore.
 4. The methodof claim 1, wherein introducing the invert emulsion fluid into theuncased section of the wellbore comprises drilling the wellbore throughthe subterranean formation with the invert emulsion fluid.
 5. The methodof claim 1, wherein the invert emulsion fluid has an average diameter ofan emulsion droplet that ranges from 0.5 to 5 microns.
 6. The method ofclaim 5, wherein the average diameter ranges from 1 to 3 microns.
 7. Themethod of claim 1, wherein the ratio of the oleaginous external phase tonon-oleaginous internal phase is less than 40:60.
 8. The method of claim1, wherein the ratio of the oleaginous external phase to thenon-oleaginous internal phase is less than 30:70.
 9. The method of claim1, wherein the alkoxylated ether acid is an alkoxylated fatty alcoholterminated with an acetic acid.
 10. The method of claim 9, wherein thealkoxylated ether acid is represented by the following formula:

where R is C₆-C₂₄ or —C(O)R³ (where R³ is C₁₀-C₂₂), R¹ is H or C₁-C₄, R²is C₁-C₅ and n may range from 1 to
 20. 11. The method of claim 10,wherein when R¹ is H, n is a value up to
 10. 12. The method of claim 11,wherein n ranges between 2 and
 5. 13. The method of claim 10, whereinwhen R¹ is —CH₃, n is a value up to 20.